Why Is Spring Prototyping Important in Engineering Design?
Specialist spring manufacture refers to the engineering and production of non-standard spring components, designed to meet exacting performance, safety, or compliance requirements. These are often required in aerospace, defence, EVs, and regulated medical technologies, where load-bearing failure is not an option.
At William Hughes, the prototyping process combines collaborative CAD support, tooling development, and physical test samples. Our engineers work directly with client design teams to simulate real-world conditions, optimise load paths, and iterate quickly. Prototyping is also essential in EV applications, where mechanical components must be integrated into increasingly modular and lightweight platforms. A single spring can determine the success of a seat mechanism, battery module locator, or connector system.
100% setting and load testing springs with the Micro Studio MC54 at William Hughes.
How Are Custom Springs Manufactured at William Hughes?
"We don't have any standard springs," said Emma Hughes, Engineering Director at specialist spring manufacturer William Hughes. "All our springs are bespoke and manufactured to customers specifications. Our customers usually contact us when they have a problem and we work with them to help them develop a spring solution that is both efficient and cost effective."
Springs generally fall into two categories, high volume, low cost springs for non-critical applications, for example, as used in the mechanism of a ball point pen - and low volume, high precision springs for critical applications such as aerospace or medical equipment. For these applications, where failure of a spring could have safety or cost implications, performance and reliability are the important criteria.
In most spring applications there are certain mechanical and physical criteria that have to be met. For example the spring has to fit within a specific space, be able to provide the required force and provide a minimum number of operations. Where the spring manufacturer can help is in ensuring that the design is viable in terms of manufacturability, and advising on the best material specification to provide a spring that will meet all the needs of the application at the minimum cost. Involving the spring manufacturer's engineering team at an early stage will lead to economies of production and handling as well as fast prototyping and functional testing.
The Dorset site is equipped with advanced CNC coiling, forming, and testing machinery, enabling efficient low-to-medium batch production. Custom springs are developed from initial CAD models, which are then validated using 2D and 3D measurement tools to ensure full compliance with tolerances.
Once the geometry is signed off, we manufacture using Kaichang CNC coilers (capable of handling wire up to 8.0mm), and where required, integrate robotic forming or hand finishing. Critical springs are tested in-line for load response, deformation limits, and fatigue cycles. Where high volumes are forecast, we also develop custom tooling in-house to reduce turnaround and cost.
Our cleanroom assembly zone further supports industries that require particulate-free packaging or Class II medical cleanliness levels. This integrated approach ensures fast feedback loops and dramatically reduces the risk of late-stage compliance failures.
What Types of Springs Are Used in EV and Aerospace Applications?
So let's remind ourselves of the basic types of spring namely compression, tension and torsion and what they do. Compression springs provide a resistive force as they are compressed, a typical example being a valve spring on a car engine. Tension springs are designed to provide a resistive force as they are stretched. They are often used as return springs where the force generated is used to return a mechanical device to its original position, for example on the throttle of an engine. A torsion spring stores energy when it is twisted, for example on the hinged lid of a compartment. Torsion springs can be combined with compression springs to provide added functionality. Depending on the characteristics required, springs can be manufactured in a wide range of materials including stainless steel, brass, phosphor bronze, beryllium copper and nickel-chrome alloys.
As an example of the way the use of springs has grown, look around the interior of a modern car or van at all the places where springs are being used. Starting with the seats, there are springs in the mechanisms to raise and lower the seat bases and adjust the angle of the backrest. All the hinged lids and latches on the storage bins and compartments will have a spring in the mechanism.
In all cases, spring design must be tuned to the specific frequency, load, and environment in which it will operate. This often means using non-linear profiles, hybrid forms, or incorporating wire forms as part of a complete sub-assembly.
In the aerospace industry springs are often used in critical applications such as oxygen systems, access hatches, and the solenoid valves used to control the hydraulic and cabin pressure systems. To meet the demanding specifications for high temperature performance, many springs need to be manufactured in exotic materials such as Nimonic, Inconel and Ni-span. These expensive materials are more difficult to work with than conventional materials and require special machinery and expertise to manufacture with high accuracy and minimum wastage.
To ensure a high standard in the aerospace industry, suppliers need to be accredited to AS9100 and this is now widely adopted as the standardised quality management system for the industry. In addition, The NADCAP (National Aerospace and Defense Contractors Accreditation Program) is an industry-managed approach to conformity assessment of 'special processes'.
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Kaichang Coiling Machine[/caption]
The Kaichang Coiling Machine extends capability up to 8.0mm wire diameter at William Hughes.
Why Choose a UK Spring Manufacturer?
Partnering with a UK-based spring manufacturer like William Hughes offers strategic advantages beyond logistics. Our close proximity to OEM and Tier 1 design teams allows for faster iterations, in-person reviews and close alignment during prototyping and product validation. It also supports compliance with UK and EU regulations.
Spring manufacturing in the UK supports supply chain sustainability goals, reducing embedded carbon, simplifying origin traceability, and minimising geopolitical risk. For many clients, this is now a critical part of ESG reporting and procurement criteria.
"The demand for specialist springs continues to grow and we are continually pushing the limits of what's possible with spring manufacture,2 continued Emma Hughes. "Our facility here in Stalbridge, Dorset is firmly established as our 'Centre of Excellence' for precision spring making and to meet these challenges we have recently moved to a new manufacturing facility. The 60% increase in space means that we can offer our customers a greater range of services and processes, and respond more quickly to their needs."
FAQ For Spring Manufacture
What is precision spring manufacture?
Precision spring manufacture involves engineering custom springs with exact tolerances, materials, and load behaviours to meet the requirements of advanced applications such as aerospace or EV systems.
Why is prototyping important in spring design?
Prototyping allows for design validation before production. It ensures the spring behaves correctly under load, fits within its housing, and meets compliance standards, reducing the risk of failure or redesign later.
Where can I source aerospace springs in the UK?
William Hughes manufactures aerospace-grade springs in its AS9100-accredited Dorset facility, offering full traceability, NADCAP audit capability, and custom design services.
What certifications are needed for aerospace spring suppliers?
For springs to be used in aerospace or medical applications, certifications such as AS9100, NADCAP, and where relevant, IATF 16949 are essential.